SPORTAGE(KM) > 2008 > G 2.0 DOHC > General Information

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SPORTAGE(KM) > 2008 > G 2.0 DOHC > General Information

General Information > General Information > General Information

IDENTIFICATION NUMBER LOCATIONS

IDENTIFICATION NUMBER DESCRIPTION

VEHICLE IDENTIFICATION NUMBER



1 3 : Make / Vehicle type KND = Kia MPV4 5 : Vehicle Line /Series JE = SPORTAGE 4x4 JF = SPORTAGE 4x26 7: Body type 72 = 4Door Sport Utility Vehicle & GVW 1821 ~ 2270kg8 : Engine type 2 = 2.0 Gasoline (G4GC) (Federal) 3 = 2.7 Gasoline (G6BA) 4 = 2.0 Gasoline (G4GC) (California)9 : Transmission type Check digit10 : Model year 4 = 2004, 5 = 200511 : Plant location K = Kwangju plant12 17 : Sequential number 000001 ~ 999999PAINT CODE

CODE COLOR

UD Clear White

S4 Grayish Silver

S6 Satin Silver

Y3 Greenish Gold

9L Natural Oliv

1L Vert Jade Pearl

K6 Smart Blue

3P Volcanic Red

6D Smokey Brown

9D Black Cherry

ENGINE IDENTIFICATION NUMBER

1. Engine fuel G : Gasoline

2. Engine range 4 : 4 cycle 4 cylinder 6 : 4 cycle 6 cylinder

3. Engine development order



B : DELTA Engine G : BETA Engine

4. Engine capacity A : 2656cc (Gosoline) C : 1975 cc (Gasoline)

5. Production year 4 : 2004, 5 : 2005, 6 : 2006

6. Engine production sequence number 000001 ~ 999999

TRANSMISSION IDENTIFICATION NUMBER

MANUAL

1. Model L : M5GF1

2. Production year 4 : 2004, 5 : 2005, 6 : 2006, 7 : 2007

3. Gear ratio H : 4.063 J : 4.533

4. Transaxle production sequence number 000001 ~ 999999

AUTOMATIC

1. Modle N : F4A422

2. Production year 4 : 2004, 5 : 2005, 6 : 2006, 7 : 2007

3. Gear ratio N : 4.042 O : 4.407 R : 4.626

4. Detailed chassification AD : 2.0 2WD BD : 2.0 4WD FD : 2.7 4WD HD : 2.7 2WD ID : 2.0 DSL 2WD + LSD JD : 2.0 DSL 4WD KD : 2.0 DSL 2WD

5. Spare

6. Transaxle production sequence number 000001 ~ 999999



WARNING / CAUTION LABEL LOCATIONS

AIR BAG WARNING / CAUTION LABEL



AIR BAG WARING / CAUTION LABEL (CONT'D)



WARNING / CAUTION LABEL (cont'd)

A : WARNINGSEE OWNER'S MANUAL.This car is equipped a side airbag for each front seat.• Do not use any accessory seat covers.• Use of other seat covers could reduce the effect of the system.• Do not install any accessories on the side or near the side airbag.• Do not use excessive force on the side of the seat.• For further information, see the owner's manual.

B : CAUTION



AIRBAG ESPE UNIT

Detach connector before unmounting. Assemble strictly according to manual instructions.

C : PASSENGER MODULE CAUTION

CAUTIONDon't open, remove or transfer to another vehicle. Risk of malfunction and bodily injury!This unit is to be installed and/or dismantled by trained personnel only. This item contains an explosive to be installedigniter.

D : SUPPLEMENTAL RESTRAINT SYSTEM (AIRBAG) INFORMATION• The airbag is a Supplement Restraint System (SRS).You must always wear the seat belts.

• The airbag system condition is normal when the "SRS" lamp in the cluster flashes approximately 6 times after theignition key is turned on and then goes off.

• If any of the following condition occur, the system must be serviced.• "SRS" lamp does not light up when the key is turned on.• "SRS" lamp stays lit or flashes continuously.• The airbag has inflated.

• The airbag system must be inspected by an authorized dealer ten years after the vehicle manufacture date shownon the certification label, located on left front door opening area.

WARNINGFailure to the above instructions may result in injury to you or other occupants in the vehicle• See the "SRS" section in Owner's Manual for more information about airbags.

BATTERY CAUTION LABEL DESCRIBTION



LIFT AND SUPPORT POINTS

When heavy rear components such as suspension, fuel tank, spare tire, tailgate and trunk lid are to be removed,place additional weight in the luggage area before hoisting. When substatial weight is removed from the rear of thevehicle, the center of gravity may change and cam cause the vehicle to tip forward on the hoist.

• Since each tire/wheel assembly weights approximately 30lbs (14kg), placing the front wheels in the luggagearea can assist with the weight distribution.

• Use the same support points to support the vehicle on safety stands.



1. Place the lift blocks under the support points as shown in the illustration.

2. Raise the hoist a few inches (centimeters) and rock the vehicle to be sure it is firmly supported.

3. Raise the hoist to full height to inspect the lift points for secure support.

1.

Fuel tank cauld be damaged or broken when using the lift in the illustration above. So, install the rubber orwooden block on the position supporting the lift and then lift up the vehicle.Minimum height of the block is 8cm.



TOWINGIf the vehicle needs to be towed, call a professional towing service. Never tow vehicle with just a rope or chain. It isvery dangerous.If the vehicle cannot be transported by flatbed, if should be towed with the front wheels off the ground. If due todamage, the vehicle must be toward with the front wheels on the ground, do not following :Manual Transmission• Release the parking brake.• Shift the transmission to neutral

Automatic Transmission• Release the parking brake.• Start the engine.• Shift to [D] position, then [N] position.• Turn off the engine.

• Improper towing preparation will damage the transmission. Follow the above procedure exactly. If youcannot shift the transmission or start the engine(automatic transmission), your vehicle must be transportedon a flatbed.

• It is the best to tow vehicle no farther than 19miles (30km), and keep the speed below 30mph (50km/h).• Trying to lift or tow your vehicle by the bumpers will cause serious damage. The bumpers are not designedto support the vehicle's weight.

Front :

Rear :



TIGHTENING TORQUE TABLE OF STANDARD PARTS

Bolt nominal diameter(mm) Pitch (mm)

Torque Nm (kg.cm, lb.ft)

Head Mark 4 Head Mark 7

M5 0.8 3 ~ 4 (30 ~ 40, 2.2 ~ 2.9) 5 ~ 6 (50 ~ 60, 3.6 ~ 4.3)

M6 1.0 5 ~ 6 (50 ~ 50, 3.6 ~ 4.3) 9 ~ 11 (90 ~ 110, 6.5 ~ 8.0)

M8 1.25 12 ~ 15 (120 ~ 150, 9 ~ 11) 20 ~ 25 (200 ~ 250, 14.5 ~18.0 )

M10 1.25 25 ~ 30 (250 ~ 300, 18 ~ 22) 30 ~ 50 (300 ~ 500, 22 ~ 36)

M12 1.25 35 ~ 45 (350 ~ 450, 25 ~ 33) 60 ~ 80 (600 ~ 800, 43 ~ 58)

M14 1.5 75 ~ 85 (750 ~ 850, 54 ~ 61) 120 ~ 140 (1,200 ~ 1,400, 85 ~100)

M16 1.5 110 ~ 130 (1,100 ~ 1,300, 80 ~94)

180 ~ 210 (1,800 ~ 2,100, 130~ 150)

M18 1.5 160 ~ 180 (1,600 ~ 1,800, 116~ 130)

260 ~ 300 (2,600 ~ 3,000, 190~ 215)

M20 1.5 220 ~ 250 (2,200 ~ 2,500, 160~ 180)

360 ~ 420 (3,600 ~ 4,200, 260~ 300)

M22 1.5 290 ~ 330 (2,900 ~ 3,300, 210~ 240)

480 ~ 550 (4,800 ~ 5,500, 350~ 400)

M24 1.5 360 ~ 420 (3,600 ~ 4,200, 260~ 300)

610 ~ 700 (6,100 ~ 7,000, 440~ 505)

1. The torques shown in the table are standard values under the following conditions :• Nuts and bolts are made of galvanized steel bar.• Galvanized plain steel washers are inserted.• All nuts, bolts and plain washers are dry.

2. The torques shown in the table are not applicable :• When spring washers, toothed washers and the like are inserted.



• If plastic parts are fastened.• If selftapping screws or selflocking nuts are used.• If threads and surfaces are coated with oil.

3. If you reduce the torques in the table to the percentage indicated below, under the following conditions, if will bethe standard value.• If spring washers are used : 85%• If threads and bearing sufaces are stained with oil : 85%

LUBRICANTSRECOMMENDED LUBRICANTS

Parts OIL & GREASE STANDARD

Engine Oil Gasoline API SL(SJ) or ABOVE,ILSAS GF3 and ABOVE

Disesl API CF 4 or ABOVE,ACEA B4 OR ABOVE

Transaxle Manual GENUINE PART MTF 75W/90 (API GL 4)

Auto DIAMOND ATF SPIII, SK ATF SPIII

Power Steering PSF 3

Brake Steering DOT 3, DOT 4 or equivalent

Coolant Ethlyene glycol base for aluminum radiator

Transaxle linkage, parking breake cable mechanism,hood, door latch, seat adjuster, tailgate latch, door hinges,tailgate hinge

Multipurpose grease NIGL grade #2

Always use Genuine Kia motors parts and recommedended fluid.Using any other type of parts and fluid can cause serious damage to vehicle.

LUBRICANTS CAPACITIES

Description 2.7 2.0

Engine oil Oil pan 4.2 (4.44, 3.70) 3.7 (3.90, 3.26)

Oil filter 0.3 (0.32, 0.26) 0.3 (0.32, 0.26)

Total 4.5 (4.75, 3.96) 4.0 (4.23, 3.52)

Cooling system 7.8 (8.2, 6.8) 6.0 (6.4, 5.31)

Manual transaxle 2.15 (2.3, 1.86) 2.15 (2.3, 1.86)

Automatic transaxle 7.8 (8.2, 6.8) 7.8 (8.2, 6.8)

Power steering 0.9 (0.95, 0.79) 0.9 (0.95, 0.79)

Capacities : [liter (U.S.qts, Imp.qts)]

SELECTION OF ENGINE OIL (Gasoline)RECOMMENDED ILSAC classification : GF3 OR ABOVERECOMMENDED API classification : SL(SJ) OR ABOVE

RECOMMENDED SAE viscosity grades :



For best performance and maximum protection of all types of operation, select only those lubricants which :1. Satisfy the requirements of the API classification.2. Have the proper SAE grade number for expected ambient temperature range.3. Lubricants that do not have both an SAE grade number and API service classification on the container shouldnot be used.

GENERAL SERVICE INFORMATIONPROTECTION OF THE VEHICLEAlways be sure to cover fenders, seats, and floor areas before starting work.

The support rod must be inserted into the hole near the edge of the hood whenever you inspect the enginecompartment to prevent the hood from falling and causing possible injury.Make sure that the support rod has been released prior to closing the hood. Always check to be sure the hood isfirmly latched before driving the vehicle.

PREPARATION OF TOOLS AND MESURING EQUIPMENTBe sure that all necessary tools and measuring equipment are available starting work.

SPECIAL TOOLSUse special tools when they are required.



REMOVAL OF PARTSFirst find the cause of the problem and then determine whether removal or disassembly before starting the job.

DISASSEMBLYIf the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be disassembled ina way that will not aggect their performance or external appearance.1. Inspection of partsEach part, when removed, should be carefulley on spected for malfunction, deformation, damage, and otherproblems.

2. Arrangement of partsAll disassembled parts should be carefully arranged for effective reassembly.Be sure to separate and correctly identify the parts to be repllaced from those that will be used again.



3. Cleaning parts for reuseAll parts to be used again should be carefully and thoroughly cleaned by an appropriate method.

PARTSWhen replacing parts, use KIA MOTORS genuine parts.

REPLACEMENTStandard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts.If removed, the following parts should always be replaced with new ones.1. Oil seals2. Gaskets3. Orings4. Lock washers



5. Cotter pins (split pins)6. Plastic nuts

Depending on their location.7. Selalant should be applied to gaskets.8. Oil should be applied to the moving components of parts.9. Specified oil or grease should be applied to the prescribed locations (oil seals, etc) before assembly.

ADJUSTMENTUse gauges and testers to adjust correclty the parts to standard values correctly.

ELECTRICAL SYSTEM1. Be sure to disconnect the battery cable from the negative () terminal of the battery.

2. Never pull on the wires when disconnecting connectors.

3. Locking connectors will click when the connector is secure.

4. Handle sensors and relays carefully. Be careful not to drop them against other parts.

RUBBER PARTS AND TUBESAlways prevent gasoline or from touching rubber parts or tubing.



MEASURING BODY DIMENSIONGS1. Basically, all measurements in this manual are taken with a tracking gauge.

2. When a measuring tape is used, check to be sure there is no elongation, twisting or bending.

3. For measuring dimensions, both projected dimensioners and actual measurement dimensions are used in thismanual.

DIMENSIONS PROJECTED1. These are the dimensions measured when the measurement points are projected from the vehicle's surface, and arethe reference dimensions used for used for body alterations.

2. If the length of the tracking gauge probes is adjustable, measure it by lengthening one of two probes as long as thedifferent value in height of the two surface.

MEASURING ACTUAL DIMENSIONS1. These dimensions indicate the actual linear distance between mesaurement points, and are used as the referencedimensions when a tracking gauge is used for measurement.

2. First adjust both probes to the same length (A=A') before measurement.

Check the probes and gauge itself to make sure there is no free play.



MEASUREMENT POINTMeasurements should be taken at the center fo the hole.

CHECKING CABLES AND WIRES1. Check the terminal for tightness.

2. Check terminals and wires for corrosion from battery electrolyte, etc.

3. Check terminals and wires for open corcuits.

4. Check wire insulation and coating for damage, cracks and degrading.

5. Check the conductive parts of terminals for contact with other metallic parts (vehicle body and other parts).

6. Check grounded parts to verify that there is complete continuity between thier attaching bolt(s) and the vehicle'sbody.

7. Check for incorrect wiring.

8. Check that the wiring is so clamped to the prevent contact with sharp corners of the vehicle body, etc. or hot parts(exhaust manifold, etc.)

9. Check that the wiring is clamped firmy to provide enough clearance from the fan pulley, fan belt and other rotating ormoving parts.

10. Check that the wiring has a little space so that it can vibrate between fixed and moving parts such as the vehiclebody and the engine.

CHECK FUSES



A blade type fuse test taps provided to allow checking the fuse itself without removing if from the fuse box. The fuse isgood if the test lamp lights up when one lead is connected to the test taps (one at a time) and the other lead isgrounded. (Turn the ignition switch so that the fuse circuit becomes operative)

SERIVICING THE ELECTRICAL SYSTEM1. Prior to servicing the electrical system, be sure to turn off the ignition switch and disconnect the battery groundcable.

In the course of MFI or ELC system diagnosis, when the battery cable is removed, any diagnostic trouble coderetained by the computer will be cleared. There fore, if necessary, read the diagnostic before removing thebattery cable.

2. Attach the wiring harnesses with clamps so that there is no slack. However, for any harness which passes theengine or other vibrating parts of the vehicle, allow some slack within a range that does not allow the enginevibrations to cause the harness to come into contact with any of the surronding parts and then secure the harnessby using a clamp.

3. If any section of a wiring harness interferes with the edge of a parts, or a corner, wrap the section of the harnesswith tape or something similar in order to protect if from damage.



4. When installing any parts, be careful not to pinch or damage any of the wiring harness.

5. Never throw relays, sensors or electrical parts, or expose them to strong shock.

6. The electronlic parts used in the computer, relays, etc. are readily damaged by heat. If there is a need for serviceoperations that may cause the temperature to exceed 80°C (176°F), remove the electronic parts before hand.



7. Loose connectors cause problems. Make sure that the connectors are always securely fastened.

8. When disconnecting a connector, be sure to grip only the connector, not the wires.

9. Disconnect connector which have catches by pressing in the direction of the arrows shown the illustration.



10. Connect connectors which have catches by inserting the connectors until they make a clicking sound.

11. When using a circuit tester to check continuity or voltage on connector terminals, insert the test probe into theharness side. If the connector is a sealed connector, insert the test probe through the hole in the rubber cap untilcontacts the terminal, being careful not to damage the insulation of the wires.

12. To avoid overloading the wiring, take the electrical current load of the optional equipment into consideration, anddetermine the appropartate wire size.

Noeminal size SAE gauge No.Permissible current

In engine compartment Other areas

0.3mm² AWG 22 5A

0.5mm² AWG 20 7A 13A

0.85mm² AWG 18 9A 17A

1.25mm² AWG 16 12A 22A

2.0mm² AWG 14 16A 30A

3.0mm² AWG 12 21A 40A

5.0mm² AWG 10 31A 54A

PRECAUTIONS FOR CATALYTIC CONVERTER

If a large amount of unburned gasolined gasoline flow into the converter, it may overheat and create a fire hazard.To prevent this observe the following precations and explain them to your customer.

1. Use only unleaded gasoline.

2. Do not run the engine while the car is at rest for a long time. Avoid running the engine at fast idle for more than10minutes and idle speed for more than 20 minutes.

3. Avoid startjump tests. Do startjumps only when absolutely necessary. Perform this test as rapidly as possible and,while testing, never race the engine.

4. Do not measure engine compression for and extended time. Engine compression tests must be made as rapidly aspossible.



5. Avoid coasting with the ignition turned and during prolonged braking.

6. Do not dispose of used catalytic converter together with parts contaminated with gasoline or oil.

BODY DIMENSION

MAINTENANCE SCHEDULE

SCHEDULE 1 NORMAL MAINTENANCE



SCHEDULE 2 SEVERE MAINTENANCE



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SPORTAGE(KM) > 2008 > G 2.0 DOHC > General Information